Slave Cylinder wont bolt in after throwout bearing replacement, need advice
 

As the title says I cant get the slave cylinder to fit into place and have the bolt holes line up. What happened was my throwout bearing blew-up, so I just picked up a new bearing from napa. As for the clutch and PP it is an ACT set put in once upon a time ago. While I had the trans out the clutch and pp look perfectly fine. but now the slave wont fit.

So I'm now left with a choice here. 1) the slave cylinder is bad and is the actual cause of the original bearing going bad. 2) the throwout bearing was killed by the ACT PP which I heard is a fairly normal thing, it is 2-3 years old, and the new bearing I picked up was packaged incorrectly.

So would be the more likely case? Either way I go the replacement will take 5 days to get to me so I would like to not waste time with the wrong choice.

Just get a new one from rock auto. I'm using SACHS clutch master and slave cylinders. Work amazing. Although be careful not to shear the bolt when bleeding it, I learned that one the hard way... Don't ask how, to this day I don't understand how it happened.

There is a slight possibility that the naps throwout bearing is different than the act supplied unit. I would call act and verify a stock replacement is okay first. Second when you installed the new bearing did you verify that the input cover/throwout carrier wasn't damaged? Also are you sure the pivot ball and arm are installed proper, in proper working function? Does the slave cylinder rod move smoothly in and out of the bore? If irs not fully retracting it could have been causing the throwout to ride on the pp and prematurely wear out. Also an internally feathered hose can flow properly when pressing the clutch pedal but restrict return causing a similar issue.

As far as I could tell, everything is in a good working order. The carrier didn't have any damage and was cleaned up. the fork seemed to operate fine with the bearing installed. I did a good check of the slave. It compresses down after being extended fine it just wont compress enough to fit even when I open up the bleed valve. only thing I found questionable was when I pulled on the end of the rod it extends with little to no effort then the piston inside would suddenly jerk out to where I pull the rod to. So the rod and the piston in the bore aren't connected? Is that normal?

sounds like the fork is jammed up on the throwout bearing. i have had it happen so i used a small prybar to pop it out, worked ok after unjamming it.

I tried prying on the fork a bit, but it didn't move up or down any.

the more I look at the old bearing makes me think the slave cylinder is just borked and not releasing enough. I don't know here is a pick of it. That was the first thing I saw when I popped the tranny and no i have no idea how the PP didn't get mutilated.

wow, that is a fucked throwout.....sounds to me like the slave was the problem. either the piston inside the slave was jammed and not fully retracting, the fork was bent, or the rod was pushing the fork and not fully releasing.....
try switching to exedy, i never had a problem with those clutches, much better than act......

Lloyd

So I just wanted to do a quick follow up. Make sure you have the right slave cylinder. If this image is correct I have been running with a NA slave on a turbo transmission.

I found it on another thread labeled as NA left T2 right.

Same thing happened to me a few weeks back turns out a na slave for a turbo tranny(that I didnt know I had) and I had the same problem

well that would create a problem.
see where the mounting holes are different?That is pushing the slave UP towards the fork.
Use the proper slave and it should be a piece of cake to put in.